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Summary of Contents for Rekluse Motor Sports Core EXP 3.0
- Page 1 INSTALLATION & USER’S GUIDE Core EXP 3.0 TorqDrive Clutch Upgrade Kit for Cable-Actuated Motorcycles Doc ID: 191-7800A Revision: 041019 ©2017 Rekluse Motor Sports Rekluse Motor Sports, Inc. support@rekluse.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS OVERVIEW ................3 INSTALLATION TIPS ............3 TOOLS ................... 4 INCLUDED PARTS ............... 4 DISASSEMBLE THE CLUTCH ..........5 CLUTCH PACK INSTALLATION ........... 6 Notes for Clutch Pack Installation: ........8 PRESSURE PLATE INSTALLATION ........10 Pressure Plate Spring Information ........11 SET THE INSTALLED GAP AND CHECK FREE PLAY GAIN .................. -
Page 3: Overview
OVERVIEW This guide shows you how to upgrade your OE (Original Equipment) core clutch parts with your new Rekluse upgraded clutch parts. The following parts are replaced: · Steel drive plates · Lining plate · EXP disk · OE Friction Disks INSTALLATION TIPS ·... -
Page 4: Tools
TOOLS 4 mm 5 mm 8 mm Torque Wrench Hex Key Hex Key Socket Hydraulic clutch Flat blade Fluid Catch Open-ended fluid Screwdriver Container Wrenches INCLUDED PARTS Each upgrade kit includes a set of TorqDrive friction disks, steel drive plates, basket sleeves, an EXP disk, and pressure plate springs. -
Page 5: Disassemble The Clutch
DISASSEMBLE THE CLUTCH 1. Turn the fuel petcock to “OFF” if applicable. 2. Lay the bike on its left side. Catch any fuel that might drain in a suitable container. 3. Use an 8 mm socket to remove the clutch cover. Pg. -
Page 6: Clutch Pack Installation
4. Remove the following parts from the clutch: · Pressure plate bolts · Lining plate · Pressure plate springs · EXP disk · Pressure plate · Clutch pack Pressure plate and lining plate Bolts and springs EXP disk Clutch pack CLUTCH PACK INSTALLATION Each clutch pack comes with a set of steel plates, a set of friction disks, basket sleeves, and an EXP disk. - Page 7 2. Inspect the clutch basket for notching. Do not install sleeves or use product with a notched basket. Notched basket tang faces can cause the sleeves to break. Do not use baskets that have been filed, machined, or modified on the tangs. Replace basket if necessary. Failure to inspect the basket and replace if necessary could result in death, serious injury, and/or property damage.
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Page 8: Notes For Clutch Pack Installation
Note: When seated in the basket, the sleeves may stick slightly above or below flush with the top of the basket. This is normal. Install all the basket sleeves Notes for Clutch Pack Installation: · The clutch pack will be replaced with all new frictions and steel drive plates. - Page 9 · Some OE basket have “half slots” at the top of the basket tangs. Rekluse products require the entire clutch pack be installed into the MAIN (deeper) basket slots. Installing the clutch pack and EXP disk in the “half slots” will cause performance issues.
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Page 10: Pressure Plate Installation
PRESSURE PLATE INSTALLATION 1. Add a light film of oil between the lining plate and pressure plate (this will help the plates stick together for ease of installation). 2. Place the new steel lining plate onto the Rekluse pressure plate by lining up the index tabs and slots. Do not reuse the old lining plate. -
Page 11: Pressure Plate Spring Information
4. Place the pressure plate springs into the assembled clutch, then insert the screw sleeves into the springs. See the following chart for spring information. Pressure Plate Spring Information The upgrade kit includes lighter pressure plate springs. You have the option of reusing your current pressure plate springs or using the new springs depending on torque capacity and clutch lever pull preference. - Page 12 c. Using three of each spring (3 red and 3 gold) will result in an in-between setup. Be sure to alternate springs when using 3 red and 3 gold to keep even pressure on the clutch. Rekluse recommends installing gold springs for a more superior lever feel and better matched torque capacity to motor output.
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Page 13: Set The Installed Gap And Check Free Play Gain
6. Using a torque wrench, tighten the pressure plate bolts to 9 ft-lb (12-N-m). SET THE INSTALLED GAP AND CHECK FREE PLAY GAIN It is very important that you understand how to set the installed gap in your new clutch, and be able to verify the installed gap by checking Free Play Gain. -
Page 14: Step 1: Set The Installed Gap
Failure to check and verify Free Play Gain can cause failure or damage to this product. Setting the correct installed gap is critical for clutch performance. Setting the installed gap and checking Free Play Gain is a 4- step process. It is important to follow each step to ensure that your new clutch functions as designed. - Page 15 4. Check for clutch lever free play. If the lever is tight against the perch, then adjust a few turns of slack into the cable and re-check your starting point. (If there is not enough adjustment at the perch, you may need to adjust using the in-line cable adjuster).
- Page 16 5. Insert the short end of the 5 mm hex key into the pressure plate adjuster, then turn it clockwise one full turn plus 2 tick marks past the starting point. Note: As you turn the adjuster, the clutch may slip and start to spin before you reach 1-full turn.
- Page 17 Note: The tops of the set screws should be flush or slightly below flush with the top of the adjuster when torqued correctly. 8. With the gap adjusted, readjust the clutch lever free play to OE specification. 9. Reinstall the clutch cover gasket or O-ring cord, then reinstall the clutch cover.
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Page 18: Step 2: Learn How To Check Free Play Gain
Step 2: Learn how to check Free Play Gain If you are familiar with Free Play Gain, check for Free Play Gain then skip to Step 3 -“Break-in the new clutch.” If Free Play Gain is new to you, follow the instructions below to help you learn this important step. -
Page 19: Two Ways To Check For Free Play Gain
If there is too much Free Play Gain, the installed gap is too small. The bike may drag and stall because it has difficulty disengaging the clutch. It may also be difficult to shift. Too much Free Play Gain will not hurt the clutch, but it will negatively affect clutch performance. -
Page 20: The Rubber Band Method
The Rubber Band Method Use the rubber band method for the initial set up. It can also be used before each ride until you feel comfortable checking the Free Play Gain using the hand method. BEFORE YOU BEGIN, verify that the bike is in NEUTRAL before checking Free Play Gain. - Page 21 c) While holding the top end of the rubber band against the handlebar, stretch the band downward, then loop it through itself. d) Pull the band through the loop, then attach it to the outside end of the clutch lever. This will take up the initial free play (slack) and put the lever in a position to detect the Free Play Gain.
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Page 22: The Hand Method
Note: It is very important the motor returns to idle before revving the engine again or Free Play Gain will not be correct. When the bike returns to idle, rest your hand across the clutch lever. Rev the engine again to 5,000-7,000 RPM so you can observe the movement while feeling for Free Play Gain with your hand. - Page 23 a) Before you begin, place the bike in NEUTRAL, start the engine and let it warm up for 2-3 minutes to idle down and warm up the engine oil. b) With the bike at idle, apply enough pressure to the clutch lever to take up the initial free play (slack) in the clutch lever.
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Page 24: Step 3: Break-In The New Clutch
Step 3: Break-in the new clutch Once you install your new clutch, it is important to break it in. A series of roll-on starts are used to break in the clutch. Follow these procedures for breaking in your clutch and any time new friction disks, EXP bases, Teflon pads, or wedges are installed. - Page 25 4. With the bike idling in first gear, slowly apply throttle to begin moving. 5. Without using the clutch lever, accelerate moderately to 10 roll-on starts approximately 5,000 RPM to fully lock up the clutch and come to a complete stop. Repeat 10 times.
- Page 26 Note: Your clutch pack will expand with heat, so final adjustment to Free Play Gain should be made when the bike is warm. Remember not to ride without sufficient Free Play Gain. 4 strokes only: It is normal for some clutch debris to be produced during break in.
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Page 27: Free Play Gain Adjustments
FREE PLAY GAIN ADJUSTMENTS Make each adjustment in small increments - one tick mark at a time. After each adjustment, recheck Free Play Gain until you achieve the optimal 1/8” (3 mm) of clutch lever movement. Symptom Reason Solution · Clutch lever moves in too far (too much Free Play Turn the pressure... -
Page 28: Maintenance
MAINTENANCE To keep your clutch performing at its best, perform regular maintenance on your bike and clutch. · Keep up with regular oil changes as per the bike manufacturer’s recommendations. Clutch performance and longevity depend on oil quality. · Oil recommendations can also be viewed under Tech Tips on our website at www.rekluse.com/support/videos/atv-mc-support-videos. -
Page 29: Disk Inspection Examples
· Inspect the dampers, and replace them if you feel any movement between the two hubs. Refer to the section on inspecting the dampers for more information. · Maintain adequate Free Play Gain. Check before every ride and adjust if necessary. ·... - Page 30 Normal Heat High Heat Excessive Heat (Blue) (Black) Friction Disks – Due to the dark color of the friction material, the friction disks will appear almost black as soon as they are put in oil. During inspection, look for glazing of the friction material.
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Page 31: Troubleshooting
TROUBLESHOOTING Performance issues If you find yourself constantly adjusting Free Play Gain or adjusting for drag, the clutch disks might be worn. Excessive heat or clutch slip can cause premature clutch failure as well. Once extreme temperatures are reached, irreversible damage will occur. -
Page 32: Exp Tuning Options
EXP TUNING OPTIONS Adjusting the engine idle speed to match your engagement setting is important and greatly affects the overall feel of how the EXP disk engages. You can tune the engagement RPM of the EXP disk by changing the spring configuration. The EXP disk comes set with the recommended “Medium”... -
Page 33: Changing The Exp Springs
Changing the EXP springs Use the following steps to change the EXP spring configuration. It is NOT necessary to disassemble the EXP halves to change springs! 1. Using a flat-blade screwdriver, push the ¼ turn pin in far enough to clear the opposite side of the EXP to unlock the pin. - Page 34 Note: To maintain even pressure, when using two different color spring sets, install one set of 3 on one side of the EXP and the remaining set of 3 on the other side. If you disassemble the EXP, the Teflon pads may fall out or be stuck to the ramp surfaces of the EXP bases.
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Page 35: Need Additional Help
NEED ADDITIONAL HELP? Website www.rekluse.com/support Frequently asked questions www.rekluse.com/faq Support Videos www.rekluse.com/support/videos Phone (208) 426-0659 Technical Support Contact Technical Support for questions related to product installation, tuning, and performance. Technical Support hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m. Mountain Time zone Email: tech@rekluse.com Customer Service... - Page 36 Auto Clutch TROUBLESHOOTING GUIDE Rekluse Troubleshooting Guide Terms Free Play Gain – The additional movement of the clutch lever under slight pressure as the RPMs are raised from idle to approximately 5000 RPM. Free Play Gain should only be checked in neutral as per the instructions.
- Page 37 Note: The “possible fixes” contained in the chart below are listed in the order of things to try first for each “symptom” Core EXP 3.0 & EXP 3.0 Troubleshooting Chart Symptom Possible Cause Possible Fix Clutch break-in Complete the recommended clutch break-in Change the oil if it’s not a clean high quality JASO MA certified...
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